The non-operation of two auxiliary engines stranded the vessel. Considering the urgency of the situation, RA Power Solutions deputed two technicians along with a specially designed onsite crankshaft grinding machine capable of grinding crankpins with small diameters and narrow widths.

In the case of the MAK 6M20 auxiliary engine, the standard diameter of the crankpin is only 152.00 mm, with a bearing width of 71 mm. The design of our onsite crankshaft grinding machine is such that it can be mounted on the crankpin diameter through the inspection window, and grinding is executed in situ.

The details of the engine are as follows:

Upon arrival on board the vessel, our technicians conducted an initial inspection of all crankpins. They found excessive ovality in all six crankpins of the MAK 6M20 engine.

We have provided a copy of the preliminary dimensional inspection report below.

All other parameters, including hardness, MPI, and deflection, were within acceptable limits. We jointly decided to grind all the crankpins, and RA Power Solutions machined them to a final size of 151.00 mm (1.00 mm undersize) as per the above dimensions.

During the stay of our technicians on board the vessel, the crankshaft of Auxiliary Engine #02 was also inspected. We detected excessive ovality showing the same pattern observed in the crankshaft of Auxiliary Engine 01.

The preliminary dimensional inspection report is provided below:

SIZE OF CR Pins Before Grinding of A/E 02
	A	Aa	C	Cc	B	Bb	Min	STD	Ovality
CR-1	151.73	151.85	151.74	151.84	151.75	151.82	151.73	152.00	0.27 MM
CR-2	151.73	151.85	151.72	151.83	151.70	151.81	151.7	152.00	0.30 MM
CR-3	151.72	151.85	151.71	151.84	151.69	151.83	151.69	152.00	0.31 MM
CR-4	151.75	151.85	151.72	151.84	151.73	151.86	151.72	152.00	0.28 MM
CR-5	151.73	151.84	151.69	151.82	151.70	151.84	151.69	152.00	0.31 MM
CR-6	151.73	151.92	151.72	151.89	151.75	151.84	151.72	152.00	0.28 MM

Our technicians ground this crankshaft and maintained the following dimensions. They successfully commissioned both engines in their presence.

SIZE OF CR Pins After Grinding A/E 02
	A	Aa	C	Cc	B	Bb	Min	Max	Ovality
CR-1	151.00	150.99	150.99	150.98	150.99	151	150.98	151.00	0.02 MM
CR-2	151.00	150.99	150.99	150.98	151.00	150.98	150.98	151.00 0.02 MM	0.02 MM
CR-3	151.00	150.99	150.98	150.98	150.99	151.00	150.98	151.00	0.02 MM
CR-4	151.00	150.99	150.98	150.99	150.99	151.00	150.98	151.00	0.02 MM
CR-5	151.00	150.99	150.98	150.98	150.99	151.00	150.98	151.00	0.02 MM
CR-6	151.00	150.99	150.98	150.98	150.99	151.00	150.98	151.00	0.02 MM

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Insitu Crankshaft Grinding Machine	Onsite Crankshaft Grinder

In Olden times, the crankshaft repair was undertaken in a workshop and on a bench-type crankshaft grinding machine. The customer had no option, but to remove the crankshaft from the engine block and send it to the designated workshop for crankshaft repair purposes. The introduction of an onsite crankshaft grinding machine has made the crankshaft repairs. Simple and less time-consuming. The grinding and polishing of crankshaft is executed onsite and in assembled condition.

RA Power Solutions manufactures the latest design of crankshaft grinding machines, which are capable of undertaking the grinding of crankpin and main journal diameters up to 700 mm. This range of machine covers most of the popular make of engines and their models installed on a vessel or in industries. The onsite crankshaft grinding machine manufactured by RA Power Solutions is designed to maintain all the parameters of the crankshaft strictly, as stipulated in the Engine manufacturer manual. The ovality, Taper, surface finish, and all the major parameters are controlled during the process of repairs.

Onsite Crankshaft Grinding & Polishing Machine	onsite crankshaft grinding machine

The onsite crankshaft grinding machine is designed in such a way that it can be operated even while sailing the vessel. This saves considerable time, as there is no requirement of holding the vessel for repairs. This is of great advantage, especially, In the case of repair of the auxiliary engine crankshaft.

The cost of the machine is very low. It is highly recommended for shipping companies, and heavy industries, having multiple numbers of power generation equipment and engine repair workshops. It is estimated that the investment of an on site crankshaft grinding machine is recovered in the execution of 2-3 jobs.

We extend training to our customers on the operation and maintenance of an onsite crankshaft grinding machine. During the training, the technicians are trained on the job of grinding and polishing of crankshaft.

On-shore and Off-Shore Crankshaft Grinding Machine

For more information regarding onsite crankshaft grinding machine, grinding of crankshaft main journal, main journal crankshaft grinding service, crankshaft journal polishing and grinding, grinding of crankshaft onsite please contact us at rajshahani@rapowersolutions.com, info@rapowersolutions.com or call us at +91 9582647131, +91 9810012383.

The post ON-SITE CRANKSHAFT GRINDING MACHINE | PORTABLE | EASY TO OPERATE appeared first on Crankshaft Grinding Repair.

On crankshaft inspection after the accident, we have observed following

Observation of crankpin and main journal of crankshaft after bearing failure

• Due to failure of crank pin or main journal bearings, on visual inspection the crankpin and main journal diameter develops line marks, pitting, and rough surface.
• In case after failure of crank pin, the main journal bearing, the engine is not stopped on time, and the radius fillet of both sides gets damaged. In some cases, we have noticed that the lubricating oil hole profile also gets lost.
• In most of cases, bearing failure results in the sticking of bearing material on the crankshaft surface. The main reason is that the bearing steel shell rubs with the crankpin and main journal diameter, temperature abnormally increases due to friction, and bearing material melts.
• Overheating due to failure of bearing shell on the crankshaft also results in black/ blue discoloration.
• The hardness increases due to abnormal heating.
• Cracks on crank pin and main journal in some of the cases are also observed.
• In case the accident is serious, it can also cause the loss of alignment of the crankshaft which becomes a serious issue for onsite repair.
• In case of above observation, certainly it is not possible to assemble the new bearings and operate the engine.
• The crankpin and main journal of the crankshaft after thorough examination requires grinding.
• We have observed that in some cases ship owners and maintenance engineers try to do the polishing of crankpin and main journal by hand which results in the repetitive failure of bearing and crankshaft.
• As a repair company with forty years of experience, we have observed that generally the crank pin and main journal diameter has to be maintained between 0.03 and 0.05 mm which is impossible to maintain by hand.
• Hence, RA Power Solutions does not recommend polishing the crankshaft by hand.

Specialization of RA Power Solutions in Crankshaft Machining and Polishing on Site

RA Power Solutions specializes in repair of crankshaft onsite without removing it from the engine block. Our technicians with onsite portable crankshaft machining equipment visit your plant or board the vessel all over the world to undertake the repairs.

With more than 10, 000 crankshaft repair jobs undertaken by us, our success rate of repair of seriously damaged crankshaft is almost 100%. We agree that there are cases where due to failure of bearing, generation of abnormal heat, multiple cracks are developed or the taper and ovality developed after the accident are higher than the last limits specified by the manufacturer. In that case there is no point in attending to the repairs.

Following steps are taken for successful repair of crankshafts of main and auxiliary engines

We give great importance to the pre-inspection of the damaged crankshaft. This is done by our experienced technicians using the state of art measuring instruments which are calibrated and certified by the agency of repute.

Pre-inspection includes the following

• Dimensional inspection of crankpin and main journal.
• Checking deflection/run-out to know the loss of alignment of crankshaft if any.
• Checking of hardness.
• Crack detection by MPI, Dye–penetrant test.
• Visual inspection
• The pre-inspection report of crankshaft is thoroughly studied by our technicians on site and strategy and successful repair is planned.
• The grinding of crankpin and main journal is undertaken removing the minimum stock possible. This helps in enhancing the life of the crankshaft.
• The removal of minimum stock from crank pin and main journal is possible only because of the use of the latest generation of onsite crankshaft grinding machine by us.
• The final inspection is undertaken and reports are prepared.

RA Power Solutions regularly undertake on site grinding of crankshaft, rotating shafts, alternator shafts, rotor shafts, turbine shafts, electric motor shafts, crankshaft machining and polishing.

We provide crankshaft grinding services in countries like Australia, Bangladesh, Cambodia, Chinese Mainland, Hong Kong, Indonesia, Japan, Malaysia, Maldives, Myanmar, New Caledonia, New Zealand, Philippines, Singapore, South Korea, Sri Lanka, Thailand, Vietnam, Afghanistan, Bahrain, Iraq, Israel, Jordan, Kuwait, Lebanon, Oman, Qatar, Saudi Arabia, Syria, United Arab Emirates, Yemen, etc.

For more information, in place crankshaft machining and polishing, polishing crankshaft please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

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